Triple ply brassiere with terry construction and method of making

ABSTRACT

A circularly knit brassiere having a body with a pair of breast-receiving cups formed from a three-ply blank. The three ply blank has a middle ply that knitted using terry loop stitches. A method of circularly knitting a three-ply brassiere blank is provided that includes knitting a middle ply, using terry loop stitches, having a first end and a second end, and knitting a body-contacting ply connected to the second end of the first ply. The method further provides for transferring held loops from the end of the body-contacting ply to the first end of the middle ply to thereby fold the body-contacting-ply inside of the middle ply. The method also includes knitting a torso-encircling welt to the end of the body-contacting ply and transferring held loops from the torso-encircling welt to the first end; and knitting an outer ply to the torso-encircling welt.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to a three ply circular knit brassiere and a method of making such a brassiere. More particularly, the present invention relates to a three ply seamless body, circular knit brassiere having selectively located padding and a method of making such a brassiere. Still more particularly, the present invention relates to a seamless body, circular knit brassiere having terry stitching in a middle ply of the three plies and a method of making such a brassiere.

2. Description of the Related Art

Modern brassieres must be designed to accommodate a variety of functions, such as, providing necessary support, comfort and aesthetic appeal. In addition to providing these expected functions, the brassiere must also be able to be used as a specialty brassiere such as a padded brassiere or an athletic brassiere. Consumers expect these attributes in a single brassiere without compromising on affordability. For manufacturers to satisfy their consumers, the desired attributes must be balanced against production costs in order to produce a garment that is competitive in the market.

Brassieres often are manufactured in the cut-and-sew manner to provide areas of distinct properties. For example, various pieces of fabric can be made of different knits, different yarns, etc. that are sewn together to form the brassiere. However, the cut-and-sew method for making brassieres can be disadvantageous because the process entails a large number of manual cutting and sewing operations that are both time consuming and costly.

Conversely, manufactures often use the circular knitting process to produce cost effective seamless blanks, that are cut, folded and sewn to quickly produce a seamless brassiere. The circular knitting process is very efficient; however, different properties often cannot be incorporated into a single brassiere.

Therefore, a need exists for a circularly knitted brassiere that incorporates different stitches, material and/or properties into the plies of the brassiere to provide enhanced functionality and comfort.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a circularly knitted brassiere having three knitted plies.

It is another object of the present invention to provide a cost effectively produced circularly knitted seamless brassiere with three plies in which each ply has different properties.

It is still another object of the present invention to provide a circularly knitted brassiere having three plies in which at least the middle ply is knitted using terry loop stitches.

It is yet another object of the present invention to provide a three-ply circularly knitted seamless brassiere that incorporates terry stitching and hydrophilic yarns.

It is a still yet another object of the present invention to provide a three-ply circularly knitted seamless brassiere that incorporates a moisture transport middle ply with terry stitching and hydrophilic yarns and a inner ply having moisture transporting properties.

It is a further object of the present invention to provide a circularly knitted three-ply brassiere having a body-contacting ply and a middle ply that are knitted using a terry stitch and an outer layer that is knitted using a decorative stitch.

It is a still further object of the invention to provide a circularly knitted seamless brassiere that minimizes the number of processing steps to produce a three-ply brassiere incorporating multiple properties into the different plies.

It is a yet further object of the invention to provide a three ply circularly knitted brassiere that uses conductive, metallic yarns in the middle ply of the breast-receiving cups to provide therapeutic and diagnostic benefits to the wearer of the brassiere.

It is a still yet further object of the invention to provide a method of making a three ply circularly knitted brassiere that uses metallic yarns in the middle ply of the breast-receiving cups to provide therapeutic and diagnostic benefits to the wearer of the brassiere.

A method of circularly knitting a three-ply brassiere blank is provided that includes knitting a middle ply having a first end and a second end and knitting a body-contacting ply connected to the second end of the middle ply by a mini-welt. The method further provides for transferring held loops from the end of the body-contacting ply to the first end of the middle ply to thereby fold the body-contacting-ply inside of the middle ply. The method also includes knitting a torso-encircling welt to the end of the body-contacting ply and transferring held loops from the torso-encircling welt to the first end; and knitting an outer ply to the torso-encircling welt.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a front plan view of the brassiere of the first embodiment of the present invention.

FIG. 2 illustrates a cross-sectional view taken along line a-a of the breast-receiving cup of FIG. 1 according to the first embodiment of the present invention.

FIG. 3 illustrates a front plan view of the middle ply according to the first embodiment of the present invention.

FIG. 4 illustrates a front plan view of a second embodiment of the middle ply according to the first embodiment of the present invention.

FIG. 5 illustrates a cross-sectional view taken along line a-a of the breast-receiving cup of FIG. 1 according to a second embodiment of the present invention.

FIG. 6 illustrates a cross-sectional view taken along line a-a of the breast-receiving cup of FIG. 1 according to a third embodiment of the present invention.

FIG. 7 a through 7 c illustrate the front plan view of the inner ply, middle ply and outer ply of the breast-receiving cup according to the third embodiment of the present invention.

FIG. 8 illustrates a cross-sectional view taken along line a-a of the breast-receiving cup of FIG. 1 according to a fourth embodiment of the present invention.

FIG. 9 illustrates a cross-sectional view taken along line a-a of the breast-receiving cup of FIG. 1 according to a fifth embodiment of the present invention.

FIG. 10 illustrates a cross-sectional view taken along line a-a of the breast-receiving cup of FIG. 1 according to a sixth embodiment of the present invention.

FIG. 11 illustrates a second cross-sectional view taken along line a-a of the breast-receiving cup of FIG. 1 according to first embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Referring to the drawings and particularly to FIG. 1, there is illustrated a brassiere generally represented by reference numeral 10 according to the present invention. Brassiere 10 has a body 12 having two breast-receiving cups 14, a torso-encircling band 16 and a pair of side panels 18. Side panels 18 are connected to each other using a conventional hook and eye fastener 24. Shoulder straps 20 are connected to body 12 by stitching 22. Brassiere 10 is circularly knitted on a pre-programmed circular knitting machine. Brassiere 10 is shown having underwires 11. However, brassiere 10 can be made as a conventional soft cup brassiere. Brassiere 10 can be circularly knitted on the needles of a conventional circular knitting machine, such as a Santoni SM8-Top2S model machine, or any Santoni machines intended for circular knitting.

Alternatively, breast-receiving cups 14 could be sewn separately and connected to side panels 18 and shoulder straps 20 to form brassiere 10. In this embodiment, side panels could be made from a single or multiple ply power net fabric to provide a very close fit to the body of the wearer.

In FIG. 2, a cross-sectional view along line a-a of a breast-receiving cup 14, is shown. Breast-receiving cup 14 has an outer ply 32, middle ply 34 a and an inner ply 36 that contacts the wearer's body. Each of the three plies is connected, preferably at a turned welt 38, at central line 40. Alternatively, turned welt 38 can be a mini-turned welt or a fold line. Middle ply 34 a and inner ply 36 are also connected by a mini-turned welt 42.

Middle ply 34 a is knitted to have different types of stitching or a stitch pattern to impart desired properties to the finished brassiere. The types of properties can depend on the desired style of brassiere.

Outer ply 32 of breast-receiving cup 14 is visible when brassiere 10 is worn. Outer ply 32 is circularly knitted to have a decorative effect. Middle ply 34 a is knitted using terry loop construction 44 a or a mock terry loop construction. Inner ply 36 is knitted using different types of stitches or a stitch pattern that is identical to middle ply 34 a. Inner ply 36 is knitted using a float stitch or a welt stitch to impart stability and support to the entire brassiere 10. This combination of stitches for middle ply 34 and inner ply 36 will provide properties of comfort and support to the wearer. The stitching of middle ply 34 a and inner ply 36 is chosen to provide optimal properties for the wearer's needs. The stitch pattern of middle ply 34 a and inner ply 36 is also selected to optimize the interaction of these plies during wear.

Referring to FIG. 3, middle ply 34 a is knitted using a true terry loop or a mock terry loop construction 44 a. Terry loop construction 44 a provides comfort and cushioning to the wearer. Terry loop construction 44 a also offers padding in the breast cup area for additional fullness and provides enhanced coverage in the breast-receiving area. Terry loop construction 44 a could be used throughout middle ply 34 a or in selected regions.

Referring to a second embodiment, middle ply 34 b shown in FIG. 4, terry loop construction 44 b could also be selectively knitted to form padding only at the lower edge of ply 34 b. In this embodiment, terry loop construction 44 b provides lifting in the breast-receiving area. To accomplish terry loop construction 44 b, the circular knitting machine is pre-programmed with the required knitting instructions.

A cross-section of the breast-receiving cup 46 of the second embodiment of the brassiere is shown in FIG. 5. Middle ply 48 and inner ply 50 have facing sides 52 and 54, respectively. Facing sides 52 and 54 have terry loop construction 56 and 58, respectively, throughout. Terry loop construction 56 and 58 in facing sides 52 and 54 provides additional comfort and padding to the wearer.

A third embodiment of breast receiving cup 60 is shown in FIG. 6. In FIG. 6, outer ply 62, middle ply 64 and inner ply 66 each have terry construction. Inner ply 66 has side 68 and terry loop construction 70. Middle ply 64 has inner side 76 having terry loop construction 72. Outer ply 62 has inner side 78 having terry loop construction 74. Terry loop construction for plies 62, 64 and 66 provide substantial comfort and padding to the wearer of the brassiere. Additionally, if heavier yarns are knitted during the knitting process of the terry loop construction 70, 72 and 74, the padding and comfort is further enhanced. Further, in each ply, terry loop construction could be knitted in to selected areas to create a desired effect. For example, in FIGS. 7 a through 7 c, inner ply 66 and middle ply 64 are knitted to have terry loop construction 70 and 74, respectively, only at lower portions of the plies. Terry loop construction at these locations would provide lift beneath the breasts of the wearer. To complement plies 66 and 64, outer ply 62 has terry loop construction 74 knit throughout to provide an overall smooth outer appearance when the brassiere is worn beneath clothing. Alternative locations of the terry knit loops are also possible to those that are shown.

In a fourth embodiment of the invention shown in FIG. 8, a breast-receiving cup 80 is for an athletic brassiere. In this embodiment, middle ply 82 and inner ply 84 are each knitted with special fibers combined into terry loop construction 84 and 88, respectively. Middle ply 82 contains yarns with hydrophilic properties such as natural fiber. Inner ply 86 contains yarns with moisture wicking properties. In combination, plies 82 and 86 transport moisture away from the body and absorb moisture to maintain desired level of comfort for the wearer. Middle ply 82 and inner ply 86 could also be knitted to incorporate functional yarns to provide anti-microbial or improved moisture wicking properties. Outer ply 90 is knitted to not only provide a decorative outer layer but also to provide the degree of support required in an athletic brassiere.

Referring to FIG. 9, breast-receiving cup 92 according to the fifth embodiment of the present invention that incorporates therapeutic benefits is shown. In this embodiment, plies 94, 96 and 98 are not knitted using terry loop construction. Ply 96 is knitted using magnetic or metallic yarns 100. The metallic yarns 100 are connected to a device 102 capable of providing electrical stimulation.

Referring to FIG. 10, a breast-receiving cup 104 according to the sixth embodiment of the present invention that incorporates diagnostic capabilities is shown. In this embodiment, plies 106, 108 and 110 are not knitted using terry loop construction. Ply 108 is knitted using metallic yarns 112 that incorporate sensors and are capable of sensing at least one biological parameter such as temperature, for example. Metallic yarns 112 are connected to a device 114 capable of interpreting biological feedback.

The preferred method of knitting brassiere of the preferred embodiment shown in FIGS. 1 and 2 will be described in reference to FIG. 11. The circular knitting of preferred embodiment commences at central line 118 of blank 116. Middle ply 120 is knitted to extend away from central line 118. In the preferred embodiment, middle ply 120 is knitted using a true terry loop or a mock terry loop construction 122 placed in selected regions of the brassiere to provide desired padding. Terry loop construction 122 could be provided throughout the entire middle ply 120 to create full padding across the entire ply. Alternatively, terry loop construction 122 could be located only in locations at the lower portions of the breast-receiving cups to provide a lift to the breast area.

After middle ply 120 is knitted, the circular knitting machine is pre-programmed to knit a mini-turned welt 124 before inner ply 126 is knitted. Mini-turned welt 124 prevents middle ply 120 and inner ply 126 from shifting when operators manually handle blank 116. Inner ply 126, in the preferred embodiment, is knitted to provide support to the wearer. Inner ply 126 can be knitted using a very tight stitch pattern, such as float stitches, to limit the degree of stretch in the fabric and to provide control. Inner ply 126 can be knitted to provide a support level for a traditional brassiere or it can be knitted to have a level of increased support if the brassiere is to be used for athletic purposes. After inner ply 126 is knitted, held loops 128 are transferred to middle ply 120 at central line 118. By transferring held loops 128, inner ply 126 is folded inside of middle ply 120 and a two-ply partially completed blank is formed.

After transferring held loops 128, torso-encircling welt 130 is knitted and will become torso-encircling band 16 as shown in the completed brassiere 10 of FIG. 1. In the completed brassiere 10, torso-encircling band 16 would be located beneath each breast-receiving cup 14 and at a lower edge of each side panel 18 to join at fastener 24. Torso-encircling welt 130 is knitted with a degree of elasticity that will prevent brassiere from shifting or slipping during wear yet provide comfort during movement. The degree of elasticity can be enhanced if the brassiere is to be used as an athletic brassiere to allow for a greater range of motion. Torso-encircling welt 130 is knitted using held loops that are transferred to central line 118 before outer ply 132 is knitted. Outer ply 132 is knitted as a decorative layer to incorporate a plain appearance or, optionally, may have unique aesthetic and recognizable knitted-in characteristics including, but not limited to, a Jacquard pattern design, geometric, stylized logo, abstract, or other designs or patterns such as florals. Outer ply 132 can be knitted using a combination of stitches to impart contour demarcations or a pattern.

The aforementioned plies 132, 120 and 126 are knitted in the described sequence because it is the most efficient method of producing the garment. This sequence maximizes the number of steps performed by the circular knitting machine and reduces the number of manual handling steps by an operator. To produce a finished brassiere 10, blank 116 is cut to form a pair of side panels 18 of FIG. 1. Each of the pair of side panels 18 is connected to a conventional hook and eye fastener 24. Breast-receiving cups 14 are connected to shoulder straps 20 at junctions 22 to offer adjustability of brassiere 10.

While the present invention has been described with reference to one or more exemplary embodiments, it will be understood that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the present invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from the scope thereof. Therefore, it is intended that the present invention not be limited to the particular embodiment(s) disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. 

1. A circularly knit brassiere comprising: a body having three plies, wherein said three plies has one ply that is a middle ply that is knitted using terry loop stitches.
 2. The circularly knit brassiere according to claim 1, wherein said middle ply is knitted using either a mock terry loop stitches or true terry loop stitches.
 3. The circularly knit brassiere according to claim 1, wherein said three plies has another of said three plies that is a body-contacting ply knitted using true terry loop stitches or mock terry loop stitches.
 4. The circularly knit brassiere according to claim 3, wherein said three plies has yet another ply of said three plies that is an outer ply having at least one decorative stitch selected from the group consisting of a Jacquard pattern, a geometric design, stylized logo, an abstract design, a floral pattern and any combinations thereof.
 5. The circularly knit brassiere according to claim 4, wherein said body-contacting ply comprises a first facing side, said outer ply comprises a second facing side, and said middle ply comprises a third facing side and fourth facing side, and wherein said first facing side faces said third facing side and said fourth facing side faces said second facing side.
 6. The circularly knit brassiere according to claim 5, wherein said first facing side, and said third facing side are knitted using terry loop stitches to increase the brassiere thickness.
 7. The circularly knit brassiere according to claim 6, wherein said second facing side in knitted using terry loop stitches to further increase the brassiere thickness.
 8. The circularly knit brassiere according to claim 3, wherein said body-contacting ply comprise fibers having moisture wicking capabilities, and wherein said middle ply comprises fibers having hydrophilic properties.
 9. The circularly knit brassiere according to claim 8, wherein said fibers of said body-contacting ply are staple or textured continuous multi-filament yarns produced from synthetic fibers and said middle ply is knitted using a natural fibers.
 10. The circularly knit brassiere according to claim 9, wherein said middle ply is knitted using a fiber having anti-microbial properties.
 11. The circularly knit brassiere according to claim 4, wherein said body-contacting ply, said middle ply and said outer ply each have zones that are selectively knitted using terry stitching.
 12. The circularly knit brassiere according to claim 1, wherein the brassiere is either a softcup brassiere or an underwire brassiere.
 13. A circularly knit brassiere comprising: a body having three plies that form an inner ply, an outer ply and a middle ply located between said inner ply and said outer ply, wherein said middle ply is knitted using terry loop stitches.
 14. The circularly knit brassiere according to claim 13, wherein said inner ply contacts the body of the wearer when the brassiere is worn.
 15. The circularly knit brassiere according to claim 13, wherein said terry loop stitch is either a mock terry loop stitch or a true terry loop stitch.
 16. The circularly knit brassiere according to claim 13, wherein said inner ply is knitted using true terry loop stitches or mock terry loop stitches.
 17. The circularly knit brassiere according to claim 13, wherein said outer ply is knitted using at least one decorative stitch selected from the group consisting of a Jacquard pattern, a geometric design, stylized logo, an abstract design, a floral pattern and any combinations thereof.
 18. The circularly knit brassiere according to claim 13, wherein said inner ply comprises a first facing side, and said outer ply comprises a second facing side, and said middle ply comprises a third facing side and fourth facing side, and wherein said first facing side faces said third facing side and said fourth facing side faces said second facing side.
 19. The circularly knit brassiere according to claim 18, wherein said first facing side, and said third facing side are knitted using terry loop stitches to increase the brassiere thickness.
 20. The circularly knit brassiere according to claim 18, wherein said second facing side is knitted using terry loop stitches to further increase the brassiere thickness.
 21. The circularly knit brassiere according to claim 13, wherein said inner ply is a body-contacting ply that comprises fibers having moisture wicking capabilities, and wherein and said middle ply has hydrophilic properties.
 22. The circularly knit brassiere according to claim 19, wherein said fibers are staple or textured continuous multi-filament yarn produced from a synthetic fiber and said middle ply is knitted using a natural fiber.
 23. The circularly knit brassiere according to claim 22, wherein said middle ply is knitted using a fiber having anti-microbial properties.
 24. The circularly knit brassiere according to claim 13, wherein said body-contacting ply, said middle ply and said outer ply each have zones that are selectively knitted using terry stitching.
 26. A brassiere comprising: a body having a breast-receiving area comprising an inner ply, a middle ply and an outer ply wherein said middle ply is disposed between said inner ply and said outer ply; and a torso-encircling band and a pair of shoulder straps connected to said breast-receiving area, wherein said middle ply is knitted using terry loop stitches.
 27. The circularly knit brassiere according to claim 26, wherein said middle ply is knitted using either a mock terry loop stitches or true terry loop stitches.
 28. The circularly knit brassiere according to claim 26, wherein said inner ply is a body-contacting ply knitted using true terry loop stitches or mock terry loop stitches.
 29. The circularly knit brassiere according to claim 26, wherein said outer ply has at least one decorative stitch selected from the group consisting of a Jacquard pattern, a geometric design, stylized logo, an abstract design, a floral pattern and any combinations thereof.
 30. The circularly knit brassiere according to claim 28, wherein said body-contacting ply comprises a first facing side, said outer ply comprises a second facing side, and said middle ply comprises a third facing side and fourth facing side, and wherein said first facing side faces said third facing side and said fourth facing side faces said second facing side.
 31. The circularly knit brassiere according to claim 30, wherein said first facing side, and said third facing side are knitted using terry loop stitches to increase the brassiere thickness.
 32. The circularly knit brassiere according to claim 30, wherein said second facing side in knitted using terry loop stitches to further increase the brassiere thickness.
 33. The circularly knit brassiere according to claim 28, wherein said body-contacting ply comprise fibers having moisture wicking capabilities and said middle ply comprises fibers having hydrophilic properties.
 34. The circularly knit brassiere according to claim 33, wherein said fibers of said body-contacting ply are staple or textured continuous multi-filament yarns produced from synthetic fibers and said middle ply is knitted using a natural fibers.
 35. The circularly knit brassiere according to claim 26, wherein said middle ply is knitted using a fiber having anti-microbial properties.
 36. The circularly knit brassiere according to claim 28, wherein said body-contacting ply, said middle ply and said outer ply each have zones that are selectively knitted using terry stitching.
 37. A circularly knit brassiere comprising: a body having a pair of breast-receiving cups formed from a blank having a body-contacting ply, an outer ply and a middle ply between said body-contacting ply and said outer ply, wherein said middle ply is knitted using yarns that are metallic.
 38. The circularly knit brassiere according to claim 37, wherein said yarns are capable of sensing at least one biological parameter.
 39. A method of circularly knitting a three-ply brassiere blank comprising: knitting a middle ply having a first end and a second end; knitting a body-contacting ply connected to said second end of said first ply by a mini-welt; transferring held loops from said an end of said body-contacting ply to said first end of said first middle ply to thereby fold said body contacting-ply inside of said middle ply; knitting a torso-encircling welt to said end of said body-contacting ply and transferring held loops from said torso-encircling welt to said first end; and knitting an outer ply to said torso-encircling welt, wherein said middle ply is knitted using true terry loop stitches or mock terry loop stitches.
 40. The method according to claim 39, wherein said body-contacting ply is knitted using true terry loop stitches or mock terry loop stitches.
 41. The method according to claim 39, wherein said outer ply is knitted using at least one decorative stitch selected from the group consisting of a Jacquard pattern, a geometric design, stylized logo, an abstract design, a floral pattern and any combinations thereof.
 42. The method according to claim 39, wherein said body-contacting ply comprises a first facing side, said outer ply comprises a second facing side, and said middle ply comprises a third facing side and fourth facing side, wherein said first facing side faces said third facing side and said fourth facing side faces said second facing side, and wherein said first facing side, said third facing side are knitted using terry loop stitches to increase the brassiere thickness.
 43. The method according to claim 42, wherein said second facing side is knitted using terry loop stitches to further increase the brassiere thickness.
 44. The method according to claim 39, wherein said body-contacting ply comprises fibers having moisture wicking capabilities, and wherein said middle ply has hydrophilic properties.
 45. The method according to claim 44, wherein said fibers of said body contacting ply are staple or textured continuous multi-filament yarn produced from a synthetic fiber and said middle ply is knitted using a natural fiber.
 46. The method according to claim 39, wherein said middle ply is knitted using a fiber having anti-microbial properties.
 47. The method according to claim 39, wherein said body-contacting ply, said middle ply and said outer ply each have zones that are selectively knitted using terry loop stitches. 